Shift Cover Disassembly/Assembly

DISASSEMBLY

1. Remove shift cover bolts, then loosen shift cover with screwdriver. To avoid damaging cover seal surface, insert screwdriver only in slots provided at the ends of the cover.
2. Raise cover enough to disengage it from alignment dowels in gear case.
3. Raise front of shift cover and lift cover up and off gear case.

ASSEMBLY

1. Clean mating surfaces of shift cover and gear case with a wax and grease remover.
2. Lubricate synchronizer sleeves with CASTROL SYNTORQ gear lubricant, then apply light coat of petroleum jelly to shift fork contact surfaces.
3. Ensure the 1-2 and 3-4 synchronizer sleeves are in the neutral position, also ensure forks in shift cover are in neutral.
4. Align and install shift cover.
5. Apply Mopar Gasket Maker or Loctite 518 to sealing surface of shift cover or gear case. Do not overapply sealer material. Excess can be squeezed into gear case and could block lubricant feed holes.
6. Apply Mopar Loc N' Seal or Loctite 242 to threads of shift cover retaining bolts, then torque to 22 ft. lbs.
7. Apply sealer to back-up lamp switch threads, then install switch and vent in shift cover. Torque lamp switch to 22 ft. lbs.
8. On 2WD models, install and index speedometer adapter in extension housing.
9. Install and torque drain plug to 30 ft. lbs.
10. Fill transmission to bottom edge of fill plug hole with Castrol Syntorq gear lubricant.
11. Install and torque fill plug to 30 ft. lbs.